PSI - Issue 57

Yixuan Hou et al. / Procedia Structural Integrity 57 (2024) 73–78 Author name / Structural Integrity Procedia 00 (2019) 000 – 000

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4. Conclusions This work presents a numerical approach to use surface profiles regenerated by a GAN architecture to predict the fatigue lifetime scatter of EBM-manufactured Ti-6Al-4V micro-sized parts. The surface roughness values of regenerated surface profiles present similar values to the input surface profiles. The FE analysis results indicate that the sharp surface defects produce severe stress concentration, which lead to early fatigue crack. The fatigue scatter characteristics of EBM-manufactured Ti-6Al-4V micro-sized parts can be reproduced using regenerated surface profiles and randomly based numerical simulations. The obtained estimated fatigue lifetime is satisfactory compared with the experimental data. A probabilistic fatigue lifetime model based on Weibull model is introduced to quantify the uncertainty of fatigue scatter, which can be served as design curves to ensure reliable fatigue design. 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